HEAT EXCHANGERS

Classification
Construction
Temperature & Pressure
Indicators
HEAT EXCHANGERS

DEF: A heat exchanger is a device that allows thermal

energy to be transferred from from a higher temperature
fluid (usually not solid)) to a lower temperature fluid.

EITHER the higher or lower temperature fluid may be

the PRIMARY fluid. The other is the SECONDARY fluid.

WHICH fluid is designated PRIMARY or SECONDARY

is determined by the system context of the exchange

Either fluid may gain/lose SENSIBLE heat (rise or

fall in temperature) or gain/lose LATENT heat
(change state)
HEAT EXCHANGERS
System context of the (heat)
exchange?
HEATER: Primary fluid does not change phase, but
increases in temperature (sensible heat)
Example: Fuel Oil
Heater
COOLER: Primary fluid does not change phase, but
decreases in temperature (sensible heat)
Example: Lube Oil Cooler
EVAPORATOR: Primary fluid changes from liquid to
vapor (absorbs latent heat)

CONDENSER: Primary fluid changes from vapor to

liquid (gives up latent heat)
HEAT EXCHANGERS
While this nomenclature is fairly
standard, sometimes you really have
toThe
think aboutHEATER
1st STAGE it. is actually a collection of
three heat exchangers
An upper heat exchanger, the (actual)
1st Stage Heater, where condensate
absorbs sensible heat and LP Bleed steam
condenses
A lower heat exchanger, the Drain
Cooler, where condensate also absorbs
sensible heat from the now condensed LP
Bleed
And steam which
a middle loses it the Gland
exchanger,
Exhaust Condenser, where gland
exhaust gives up latent heat to the
condensate which retrieves it as sensible
heat
HEAT EXCHANGERS
Irrespective of mode of heat transfer
(sensible/latent), heat exchangers may be
classified by the degree of separation of
primary
DIRECT & secondary
CONTACT: Mixingfluidsof primary & secondary
fluids, with one typically changing phase
Example: the DC Heater mixes auxiliary
exhaust steam witch condensate. The system
context is that the condensate is the primary
fluid which is heated but does not evaporate.
Example: an attemperator where
superheated steam is desuperheated (but does
not condense) by an evaporating liquid
(condensate or feedwater)
INDIRECT CONTACT: Primary/secondary fluids
exchange heat through a (usually metal) boundary that
separates them
Example: just about any heat
exchanger you can think of other than
the above
HEAT EXCHANGERS
And connection to
gland exhaust
condenser (?)

NOTE: vent
condenser (!)
within DC Heater

The DEARATION FEED

TANK (DFT) is a (and
since the only, the)
Direct Contact (DC)
Heater
HEAT EXCHANGERS
INDIRECT CONTACT: Primary/secondary fluids
exchange heat through a (usually metal) boundary that
separates them

2 PRINCIPAL CLATEGORIES: Based on

construction of the separating barrier

Shell and Tube where one fluid (primary or

secondary, warmer or cooler) passes through a
bank of tubes, and the other fluid (contained in
a shell) passes over the tubes

Flat Plate where primary & secondary fluids

flow through many small passages on either side
of a corregated plate. Typically many plates are
stacked together in a single flat plate heat
exchanger with primary & secondary fluids
flowing in the passages of alternating plates
HEAT EXCHANGERS
MANY ARRANGEMENTS: of
shell & tube heat exchangers may be
found, each defining in some way, a
subcategory

Tube arrangement is one

such way of distinguishing;
straight of U-tube (not You-
tube), single or multi-pass
Tube-tube sheet connections
are critical in these heat
exchangers and are the main
source of failure (leakage)
HEAT EXCHANGERS Classification by
DIRECTION of FLOW:

Counterflow exchangers have some theoretical thermodynamic

advantage in liquid-liquid or gas-gas exchangers (SENSIBLE HEAT)
Heat transfer is usually better when a flow moves across tubes than along
their length. Hence, cross-flow is often the preferred flow direction,

The baffles serve to induce turbulent

mixing and a cross-flow component,
both of which increase the convection
coefficient.
HEAT EXCHANGERS
DESIGN DETAILS: of shell & tube heat exchangers
focus on two principle areas
Tubesheet support: of which there are three
main designs
o U-Tube exchangers: permit unlimited thermal expansion &
tube bundle can be removed for cleaning. Internal cleaning of
tubes is difficult (use with clean tube-side fluids)
o Fixed tube sheet: tubesheet is welded to shell. Easy internal
tube cleaning, external cleaning by chemical cleaning only. Often
requires incorporating an expansion bellows in shell.
o Floating tube sheet: Front tubesheet fixed as above, rear
tubesheet allowed to float. Any number of sealing arrangements
may be employed
Tube-Tubesheet connections: of which
there are four basic types
o Packed joints: somewhat obsolete
o Expanded joints by far the most common; several methods of
expanding available rolled being the most common
o Welded joints Impact (explosive), butt or edge weld. Expand &
weld becoming popular
HEAT EXCHANGERS
HEAT EXCHANGERS Rolled Expansion Joints
Cleaning and degreasing the surfaces of
the holes in the tube sheets, and the tube
ends Smoothness and cleanliness of
adjacent surfaces of a hole and a tube are
essential to a tight and durable connection
between a tube and a tube sheet.
Inserting the tubes Tubes are
inserted using guides that prevent the
tubes from becoming blocked on
partitions and from being damaged.

Blocking the tubes in the holes By fixing the tube and

eliminating the space between the tube and the hole in the tube
sheet, one can prevent the tube from sliding and turning during the
process of expanding.

Finishing of the tube ends

Process allowances of tubes are
removed with facing heads. Sockets
can also be made on such faced
tubes, or they can be rounded of
HEAT EXCHANGERS 1st STAGE HEATER
LP
BLD

1st STG HEATER

GL.EXH.COND

DRAIN COOLER

SG-0025
HEAT EXCHANGERS
The Flat Plate Heat Exchanger
FLAT PLATE: FLAT PLATE:
many, small many, small
passages carrying passages carrying
hot fluid cold fluid

Adjacent, alternate plates: heat

transferred from warmer to cooler fluid
HEAT EXCHANGERS
The Flat Plate Heat Exchanger
End view

Actual construction
HEAT EXCHANGERS
Flat Plate Distiller
FEED
PUMP 1.1 psia

FPHX #2: 104oF

F.W. PUMP
CONDENSER
VAPOR

180oF

FPHX #1:
EVAPORATOR

ENGINE J.W.
MAIN PUMP

TSES VI

AIR EJECTOR / BRINE EDUCTOR

HEAT EXCHANGERS
TSES VI Flat Plate Distiller (NYREX)
FEED
PUMP 1.1 psia

150 psi
FPHX #2: 104oF
Aux Stm F.W. PUMP
CONDENSER
VAPOR

180oF
FPHX #3
GLYCOL FPHX #1:
HTR EVAPORATOR

Glycol
J.W.
Drain Circ
PUMP
Pump
TSES VI

AIR EJECTOR / BRINE EDUCTOR

HEAT EXCHANGERS
Flat Plate Distiller (NYREX)
HEAT EXCHANGERS

Monitoring Heat
exchangers. we want to know:
TEMPERATURES
PRIMARY (IN & certainly OUT)
SECONDARY (possibly IN & OUT)
PRESSURES
PRIMARY (possibly IN & OUT)
SECONDARY (likely IN & maybe OUT)
FLOWS
we typically infer flows from Ps &
Ts
HEAT EXCHANGERS
TEMPERATURES
Thermometers of
course:

Bi-
metal Liquid-in-glass
But
also:
THERMOCOUPLES
THERMISTORS
Resistance Temp Detectors (RTDs)
PYROMETERS
HEAT EXCHANGERS
TEMPERATURES THERMOCOUPLES
o Thermocouples consist of two wire legs made from diferent metals.
o The wires legs are welded together at one end, creating a junction where
the temperature is measured.
o When the junction experiences a change in temperature, a voltage is
created, which can then be interpreted using thermocouple reference
tables
o There are many types of thermocouples, each with its own unique
characteristics in terms of temperature range, durability, vibration
resistance, chemical resistance, and application compatibility.
o Type J, K, T, & E are Base Metal thermocouples, the most common
types of thermocouples.
o Type R, S, and B thermocouples are Noble Metal thermocouples,
which are used in high temperature applications

Type T Temperature Range:

Thermocouple grade wire,
-454 to 700F (-270 to 370C)
Extension wire,
32 to 392F (0 to 200C)
HEAT EXCHANGERS
TEMPERATURES THERMISTORS
o Thermistors are inexpensive, easily-obtainable temperature
sensors.
o They are easy to use and adaptable.
o Circuits with thermistors can have reasonable outout
voltages - not the millivolt outputs thermocouples have.
o Because of these qualities, thermistors are widely used for
simple temperature measurements.
o They're not used for high temperatures, but in the
temperature ranges where they work they are widely used
HEAT EXCHANGERS
TEMPERATURES
Resistance Temperature Detectors (RTDs)
o RTD elements consist of a length of fine coiled wire wrapped
around a ceramic or glass core. The element is usually quite
fragile, so it is often placed inside a sheathed probe to protect it.
o The RTD element is made from a pure material whose resistance
at various temperatures has been documented (not a solid state
device as is a thermistor).
o The material has a
predictable change in
resistance as the
temperature changes;
it is this predictable
change that is used to
determine
temperature.
HEAT EXCHANGERS
TEMPERATURES PYROMETERS
A radiation thermometer, in very simple terms,
consists of an optical system and detector.
o Infrared radiation thermometers/ pyrometers, by specifically measuring
the energy being radiated from an object in the 0.7 to 20 micron
wavelength range, are a subset of radiation thermometers.

o These devices can measure this radiation from a

distance. There is no need for direct contact between
the radiation thermometer and the object, as there is
with thermocouples and resistance temperature
detectors (RTDs).
o Radiation thermometers are suited especially to the
measurement of moving objects or any surfaces that
can not be reached or can not be touched.
HEAT EXCHANGERS
PRESSURES BOURDON TUBE GAGES

o Unpressurized tube
elliptical in cross-
section
o Sensed pressure
forces cross-section
to become more
round
o Which causes
curved tube
o touncoil
Tube may be
connected to
pointer (as shown)
or to strain gage
with digital read-out
HEAT EXCHANGERS
PRESSURES BOURDON TUBE GAGES

o Bourdon tubes work best liquid filled & must be protected

from excessive temperature, physical shock and caustic fluids
HEAT EXCHANGERS
PRESSURES BOURDON TUBE GAGES
o Pressure gauge siphons are used
to protect the pressure gauge from
the efect of hot pressure media such
as steam and also to reduce the
efect of rapid pressure surges.
o The pressure medium forms a
condensate and is collected inside
the coil or pigtail portion of the
siphon.
o The condensate prevents the hot
media from coming in direct contact
with the pressure instrument.
o When the siphon is first installed, it
should be filled with water or any
other suitable separating liquid.
HEAT EXCHANGERS
PRESSURES UNITS

English Units:
psia, psig, H2O, Hg, Hg(VAC)
1 standard atmosphere (atm) =
14.7 psia 30.01Hg (60oF) 39.3ft (H2O @ 60oF)

Other Units: 1 atm =

760 mmHg (0oC) 101.325 Pa 1.01325 bar
1.0332 Kg/sq.cm 101325 N/sq.m
HEAT EXCHANGERS
PRESSURES COMPOUND GAGE
Same name, 2 different
items

VAC in Hg & Refrig Gage: inner red

PSIG (< 1 atm) scales are Sat. Temps corres-
ponding to indicated press